Method of making a granular media water filter

ABSTRACT

Granules comprise binder-agglomerated active particles for liquid treatment or filtration. Each granule has a center core of a material that itself has binding properties without the addition of other binders or sprays or adhesives, or, alternatively, each granule comprises a matrix of active materials stuck together with the binder. The binder structure preferably ranges from a non-uniform matrix of binder formed by heat-deformed binder particles, to a clump of binder particles generally retaining the original shape or the binder particles, to non-continuous connectors of binder between active particles. The invented two-part media has high surface area per volume of media, which, because the outer surface and inner void surfaces of the particles are preferably substantially covered with active particles, translates to high activity for the preferred treatment process. Therefore, while a mixture of active particles may be used and a mixture of binders may be use, each media granule preferably consists only of a matrix, clump, or plurality of connectors of binder coated with active particles, with preferably no support for the active component other than the binder material.

This application is a continuation of Ser. No. 12/016,992, filed on Jan.18, 2008, and issued as U.S. Pat. No. 7,740,141 on Jun. 22, 2010, whichis a continuation of Ser. No. 10/509,439, filed on Jun. 3, 2005, nowabandoned, the entire disclosure of which is incorporated herein by thisreference, wherein Ser. No. 10/509,439 claims priority ofPCT/US2003/008755, filed Mar. 24, 2003, and wherein said PCT applicationclaims priority of U.S. Provisional Application 60/367,028, filed Mar.23, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a high-surface-area, high-activity granularmedia for liquid filtration and/or treatment. More specifically, thepreferred embodiment relates to a two-part media composition of binderand active particles, without a conventional solid support core. Themedia comprises binder-agglomerated active materials, wherein a bindermaterial holds together particles of active component so that a highpercentage of the active particles are exposed to the liquid beingfiltered/treated. The granules may take the faun, for example, of aninner core and/or matrix of binder that supports an active componentcoating, or the form of active particles bound together by particles,globules, or amorphous shapes of binder.

2. Related Art

Particulate materials have been disclosed for removal of heavy metalcontaminants from aqueous solutions and vapor phase systems, forexample, in Lisenko (U.S. Pat. Nos. 5,639,550 (“'550”) and 5,603,987(“'987”)). Lisenko '550 illustrates in FIG. 1A a prior art media, suchas found in U.S. Pat. No. 5,277,931, in which a porous particle (S) isfirst sprayed with an aqueous basic material (B) and subsequentlysprayed with a concentrated aqueous acidic solution of a source ofsuitable metallic ions. The sprayed-on source of suitable metallic ionsis the primary material (P), that is, the active material. Such spray-onprior art media are described by Lisenko as exhibiting high attrition.

Lisenko discloses a particulate media comprising three-part granules(G′, FIG. 1B), wherein each granule is made of a large support material(S), and a primary material (P) bound to the outer surface of thesupport material by a binder material (B). In Lisenko, the softeningtemperature of the binder is less than the softening temperature of thesupport material and less than the softening temperature of the primarymaterial. Thus, Lisenko discloses a three-part composite, wherein thecenter core is a solid particulate that holds two layers on its outersurface, an intermediate layer of binder and an outer layer of primaryfiltration material. In other words, the three-part media is a solidsupport with a solid primary material “stuck” to the support by a layerof binder that is relatively very thin compared to the diameter of thesupport material.

In three-part granules, the support material preferably has preferablysubstantially uniform particle diameters which are substantially greaterin size than the particle diameters of the primary material. The supportmaterial may be granulated activated carbon, glass beads or bubbles;porous or non-porous volcanic media; plastic beads or pellets; plasticfibers; wood fibers; carbon fibers; ceramic media; fired or unfiredclay; diatomaceous earth; metal particles; ferro magnetic material;silica gel; magnetic stainless steel; organic fiber; cellulose fiber;acrylic fiber; and silicon carbide.

The primary material for the three-part granules may be inorganichydrated metal oxides, amorphous metal silicates, zeolite and mixturesthereof, and more preferably inorganic hydrated titanium oxides orsilicates, inorganic hydrated tin oxides or silicates and mixturesthereof, and most preferably titanium silicate, tin silicate andmixtures thereof, and most preferably titanium silicate, tin silicateand mixtures thereof. The primary material is chosen for a desiredproperty for treatment, such as ion exchange capacity or metals removal.Preferably, the primary material may be micronized or powdered in form.

The binder in a three-part granular media is chosen from a wide varietyof materials including crystalline thermoplastic polymer, thermoplasticpolymer, crystalline polymer and mixtures thereof, preferablypolyolefins, polyamides and mixtures thereof, and specificallypolyethylene, polypropylene, ethylene vinyl acetate and mixturesthereof. The binder material may be provided in particulate form to theprocess of manufacturing the composite media.

Typical relative sizes for the components of three-part granular areillustrated in FIG. 5A. The large support particles are shown in the4-100 mesh range (from very large particles down to 140 microns), theprimary particles are shown in the 230-500 mesh range (approximately 60down to 25 microns) and binder particles are shown in the 450-500 meshrange (approximately 30 microns and smaller).

During manufacture of the three-part granular media, the primaryparticulate, binder particulate, and support particulate are mixed andthe mixture is heated to a temperature within about 25 degrees of thesoftening temperature of the binder material. This way, the bindermaterial does not soften to the point where it readily flows and masksthe internal pores of the primary and support materials. This procedurecauses the binder material to lose shape and become sufficiently viscousto adhere the primary particles to the support material, with the binderin-between. Then, the mixture is cooled to ambient whereby adhesion ofthe binder material between the primary material and the supportmaterial becomes substantially permanent. The result is a particulatemedia with particles having diameters generally equal to the diameter ofthe support material plus the layers of binder and primary material.

Still, there is needed an improved particulate filter/treatment mediathat is strong, very high in active surface area, and economical andconvenient to make and use. The present invention serves these needs.

SUMMARY OF THE INVENTION

The invented media comprise binder and active materials agglomeratedtogether to form media granules. The agglomerated materials preferablycomprise only two components, namely, the binder plus primary activematerial adhering to, or connected by, the binder. These agglomeratedmaterials may comprise a core/support of polymeric binder holding activematerials on the binder surface and/or active materials stuck togetherby relatively small and discontinuous amounts of binder. The inventedgranules have a large surface area of active material exposed to theliquid being filter/treated, because of the two-component structure andbecause of the presence of many void spaces in each granule that provideaccess to active sites in the interior of the granule. The inventedgranules of agglomerated materials preferably do not include a largesolid support coated by an intermediate layer of binder and an outerlayer of active material.

Whether a granule takes the form of a coated matrix of binder, coatedcores of binder stuck together, or active particles stuck together byrelatively small and discontinuous amounts of binder, each granule hasmany interior void spaces or channels and a large surface area ofexposed active component. The exposed active material comprises both theactive material on the outer surface of the granule and the activematerial on the interior surfaces of the granule that surround anddefine the void spaces. Because preferably none of the granule mass orvolume is a conventional solid support core, a greater percent of themass and volume of each granule is active component. Because there aremany voids extending into and even all the way through the granule, theactive component is easily accessible to the liquid being filtered.These features result in the granule exhibiting higher activity thanconventional three-part media granules while still exhibiting goodpressure drop characteristics and good flowrates even under gravity flowconditions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are prior art filtration media, including a solidsupport, a binder material, and a primary material.

FIG. 2 is a depiction of one embodiment of a media according to theinvention with a binder matrix coated with active primary material.

FIG. 3A is a depiction of another embodiment of the invented granularmedia with a plurality of generally spherical binder cores each coatedwith active primary material, and the binder cores adhering to eachother or connected by additional binder.

FIG. 3B is a depiction of another embodiment of the invented granularmedia comprising active primary material connected by small,discontinuous connectors of binder.

FIG. 4 is a depiction of another embodiment of the invented media, whichhas been compressed and then re-separated into granules.

FIG. 5A schematically illustrates particle sizes for manufacture ofgranular media according to the prior art.

FIG. 5B schematically illustrates particle sizes for manufacture of oneembodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Referring to the Figures, there are shown prior art three-partfiltration media granules, and some, but not all, of the embodiments ofthe invented binder-agglomerated granular media. While the preferredmedia according to the invention may be hereafter and in the claimsreferred to as a “treatment media,” this term includes media for manypurposes, including filtration, additive addition, adsorption, metalsremoval, and other treatments of fluid streams, including preferablyboth liquid and gases.

The preferred media granule is made from two components, which are abinder that becomes a core/support or a connecting means, and a materialthat is active to accomplish the filtration and/or treatment of thefluid. Because the core/support/connecting means is a binder material,no further component besides these two is necessary, that is, no solidsupport particle is needed. The preferred structures of the inventedgranules are 1) a non-uniformly-shaped support matrix of binder, towhich the particulate active material adheres, and which has manyinterior void spaces or channels; 2) a plurality of cores of binder(retaining generally the original shape of the binder particles) coatedwith particulate active material, wherein the plurality of coated coresadhere together to form a single granule due to additional binderconnecting the cores together or because portions of the binder coresare exposed and stick together; 3) a plurality of active particles stucktogether by a relatively smaller amount of binder in discontinuousportions; and 4) structures that are somewhere between or a combinationof these structures. In a much-less preferred embodiment, each granulecomprises a single, generally spherical core of binder material coatedwith particulate active material.

The binder has a melt index in a range that allows it during manufactureof the media to 1) deform sufficiently so that a plurality of binderparticles adhere together to form clumps/groupings of particles or amatrix of binder and/or 2) become sufficiently tacky for active materialto adhere to it. Cooling of the granules at or near the end of themanufacturing steps serves to solidify/firm-up the binder in the“clumped,” “matrix,” or “connecting” shapes, each having internal voidsand channels.

Whether the “clumped,” “matrix,” and “connecting” binder shapes areachieved in the granules depend chiefly on the relative amounts ofbinder and active particles, and on the softening point/melt index ofthe binder, the temperature of the manufacturing process, and the sizesand type of binder and active materials. With higher melt index and/ormore mixing time or higher temperature during the heating step, andoptionally with compression, the binder particles tend to become a“matrix,” which takes the form of a plurality of binder particlessticking together and substantially losing their original shape todeform or “smear” into a network of irregularly-shaped portions withinternal voids. With lower melt index and/or less mixing time or lowertemperature during the heating step, and with low or preferably nocompression, the binder particles tend to stick together but generallyretain their original shape. With lower amounts of binder relative toactive particles, binder particles tend to stick in between and serve asconnectors between several active particles, rather than to stick tomultiple other binder particles to form a binder clump or matrix.

The two components of the granules may be selected from lists ofconventional binders and primary active materials. The binder ispreferably a polymeric binder that is inactive or inert to the fluid,preferably performing no treatment or chemical action on the fluid beingtreated, and preferably no physical action upon the fluid being treated.The coating material is preferably an active material chosen for aspecific purpose or purposes of treatment. Examples of active coatingmaterials include metal sorbent or carbon. Also, metal shavings orparticles may be effective active material.

Referring specifically the Figures:

FIG. 1B, prior three-component granules G′ are designed to have,relative to each other, a large support particle (S), a outer layer ofmedium size primary particles (P), and small binder particles (B) meltedtogether into a middle layer. When these three particle sizes are mixedand heated, the desired prior art product is produced, that is, a largesolid core with active primary ingredient stuck to it's outer surface bythe binder.

Referring to FIGS. 2-4, the preferred methods and compositions of theinvention result in a very high active surface area per volume of media,with good pressure drop characteristics. This high surface results fromsmall binder particles and small active (or “primary”) materials coatedonto the binder material, rather than relying on primary material beingcoated onto binder along the surface of a large, solid core. Theinvented media attains this high surface area withacceptable-to-excellent pressure drop, because the large, solid core ofeach prior art granule is replaced with a clump or matrix of binder,having many internal voids and channels that allow liquid flow into andthrough the granule, or with small, discontinuous amounts of binderconnecting portions of active particles.

Referring specifically to FIG. 2, there are shown cross-sectional viewsof media granules 20 according to one embodiment of the invention,wherein the center core of granules 20 comprises a binder matrix 22,that is, a nonuniform structure of binder (cross-hatched in FIG. 2)having multiple voids and channels 24. The embodiment of FIG. 2 isformed according to an embodiment with higher melt index (for example,10 g/min) and a temperature selected to deform the binder withoutencapsulating the active particles. Primary active particles 26 adhereto the binder matrix 22, coating part or all of the outer surface 32 ofthe matrix and part or all of the inner surfaces 34 of the matrix, thatis, the surfaces surrounding and defining the voids and channels 24. Asone may see from FIG. 2, the binder matrix 22 does not take the form ofa uniform shape or spheres, but rather a network of irregular shapeswith internal voids. The binder particles in the granules 20 of FIG. 2have softened and deformed enough to connect together and substantiallylose their original shape.

In FIG. 3A, the media granules 50 according to the invention have acenter core of binder particles that have softened and deformed lessand, although they stick together, they retain more of their generallyoriginal shape. The binder particles, therefore, form a core that is a“clump” or “cluster” or “grouping” 52 of binder (cross-hatched in FIG.3A), with internal voids and channels 54. Primary, active particles 56adhere to part or all of the outer surface 62 of the clump 52, as wellas part or all of the inner surface 64 surrounding and defining voidsand channels 54. This clumping or grouping effect (as opposed to thematrix) is believed to be a result from one, or a combination ofseveral, of the factors of: a lower temperature, lower agitation orstirring time, lack of compression, very low met index, and/orrelatively high ratios of binder to active materials.

FIG. 3B illustrates media granules 150 wherein the binder particles orglobules 152 (shown in cross-hatching) act to connect the activeparticles 156 together by sticking between the active particles but notsticking to many other binder particles or globules. In suchembodiments, globules of binder are dispersed between the activeparticles, but tend not to form a continuous matrix or continuousclumping of binder. Like the matrix or clumping binder structures, this“connector” binder structure also results in large numbers of voids andchannels 154 through each granule for increased surface area and goodpressure drop. Such embodiments may be made, for example, by combiningrelatively small amounts of binder with the active particles, as inExample I and II below.

FIG. 3B illustrates granules that are made from relatively large,irregularly-shaped activated carbon particles (156) agglomeratedtogether by smaller particles/globules of binder (152). In suchembodiments wherein relatively small, discontinuous portions of binderconnect relatively large particles of active material, there are manyvoids in each granule, as well as channels that extend all the waythrough the granule.

The preferred embodiments of the invention involve no compression of themixture of binder and active particles. However, some less-preferredembodiments may include a limited amount of compression, as illustratedin FIG. 4. Already-formed granules are treated in a compression step,for example, in the 1-30 psi range, while the granules are still abovethe binder's softening point, followed by separating and sizing thegranules to the desired granule size. One may see, in FIG. 4, that theactive particles 76 are more uniformly adhering to the binder core 72(cross-hatches), and more deeply embedded in the binder material both atthe outer surface 82 of the granule and at the inner surface 84 of thevoids and channels 74. There are still many internal voids and channels74 in the granules 70 that, as in the other granules 20, 50, areaccessible to liquid being filtered.

Many different sizes, types, and combinations of binders and activematerials may be used in the binder-agglomerated granules of theinvention. Active materials may be in the size range of 850 microns(about 20 mesh) down to one (1) micron, for example, with a preferredsize range of 300 microns (about 50 mesh) down to one (1) micron. Someembodiments are very effective with smaller active materials of only 150microns and smaller. Preferred active particles may be activated carbon,for example, 50×20 mesh carbon; lead sorbents; synthetic and naturalzeolites; alumina oxides; titanium hydroxides; hydrated metal oxides;resins; charged polymers with higher softening point than binder; andmixtures of the same. Other active particles for various water treatmentprocesses may be used, as will be known to those of skill in the artafter understanding this Description and Drawings. For example, theprimary material may be inorganic hydrated metal oxides, amorphous metalsilicates, inorganic hydrated titanium oxides or silicates, inorganichydrated tin oxides or silicates and mixtures thereof, titaniumsilicate, tin silicate and mixtures thereof, titanium silicate, tinsilicate and mixtures thereof. Primary material may be micronized orpowdered in form, for example.

The binder according to the invention may be, for example, thermoplasticpolymer, thermoplastic polymer, crystalline polymer and mixturesthereof, preferably polyolefins, polyamides and mixtures thereof. Forexample, polyethylene, polypropylene, ethylene vinyl acetate andmixtures thereof are especially useful. The binder material may beprovided in particulate/powdered form, for example. Binders according tothe invention most preferably have Vicat Softening Points in the rangeof 150-400 degrees F., whereas the active materials included in thegranules according to the invention have softening points greater than400 degrees F., and typically, much greater than 400 degrees F.

The binder particles may be provided in a wide range of diameters, forexample, 10-10,000 microns, with the preferred binder particles havediameters in the range of about 1-150 microns and more preferably in therange of about 75-150 microns or about 100×200 standard U.S. mesh size.

During the heating step used to binder-agglomerate the active particles,the binder particles preferably do not flow, but do soften and/or deformfrom their original shape to an extent that forms the preferred bindermatrix, the connection of a plurality of binder cores together to form agranule, and/or the connection of active particles with discontinuousportions of binder. Preferred binder particles exhibit a melt index inthe range of 10 g/min. Binder particles with a melt index in the rangeof 1-10 g/min may be appropriate for forming a binder matrix as in FIG.2. Binder particles with a very low melt index in the range ≦1 g/min.are more likely to form binder structures shown as in the FIG. 3 andFIG. 4 embodiments. Binders with what is called a “zero” or very lowmelt index binder, that is, preferably less than or equal to 1 g/10minute, as measured by conventional standard melt index tests, areexpected to exhibit ultra high activity but slightly higher finescontent. (Melt Index is measured by ASTM D1238 or DIN 53735 at 190degrees C. and 15 kilograms.)

FIG. 5B illustrates schematically examples of size ranges of theinvented two-component system, wherein the active particles are in therange of about 1-150 microns (100-500 mesh) and the binder particles arealso in the range of about 1-150 microns. Preferably, there are noparticles larger than the primary particles and binder particles, thatis, there are no large support particles such as are typical in thethree-component granules. As may be seen in FIG. 5B, there may be somesmall percentage of materials (the tails that are below about 5 wt %)outside of the preferred range of mesh, depending on the method ofmanufacture, sizing, screening, and handling.

The granules according to the invention provide high activity and highsurface area due to the interior voids and channels that expose highsurface area to the water or liquid being treated. Good pressure drop isachieved by sizing the granules to an appropriate range that does notrestrict flow through a bed of the granules. The total diameter of amedia granule according to many embodiments of the invention are in the4 to 200 mesh range (75 micron up to about 4700 micron), and preferablyin the 4-100 mesh range (140 micron up to about 4700 micron). Thisresults from many 1-150 micron (or even larger) binder particlessticking together and becoming coated with the primary active material(1-150 micron or even larger). In especially-preferred manufacturingprocesses, sizing is preferred in order to separate any the >1700 microngranules into more than one 250-1700 micron granules.

To make the preferred embodiment, two powders are mixed together, onebeing a powdered binder and one being a powdered carbon or sorbent orother active material. Many embodiments of said mixtures, and hence ofthe resulting granules, consist of 8-50 wt-% binder and 92-50 wt-%active material, and no other components. More preferably, saidmixtures, and hence resulting granules, consist of 8-35 wt-% binder and92-65 wt-% active material, with no other components.

The mixture is heated to a temperature at which the binder softensenough to form the binder matrix, clump, or connectors, and the activematerial coats the binder matrix or clumps or sticks together due to thebinder. This temperature is typically in the range of 275-350 degrees F.for many of the preferred binders, but may be even higher, for example,275-425 degrees or even up to 500 degrees F. The target temperature iswithin about 25 degrees of the Vicat softening point, but this may belowered or raised depending upon the particular granule characteristicsdesired. The quality and effectiveness of many embodiments of theinvention are not extremely sensitive to what temperature is chosen.With many polyolefin binder particles, which are white before heating,one may observe when the particles reach an appropriate temperature dueto the particles losing their white color and becoming clear.

While still warm, the material resulting from the heating and agitatingstep is sized, and the mixture is cooled to ambient by any of variousmethods, to obtain the invented media. Sizing the heated mixture whilewarm, rather than after cooling, serves to limit fines production. Thisis believed to be because the breaking apart of warm granules to thedesired size granule comprises a separation or pulling apart of portionsof the binder, rather than breaking of solidified binder or activeparticles, and does not produce significant fines. Sizing a cool mixture(or a cool compressed block of granules) is believed to break binderand/or active particles, and produces more fines of binder and/or activematerial.

For use, the invented media is loaded into a cartridge, filter, tank,housing or other vessel with appropriate support and screening andinfluent and effluent means directing fluid to the media and away fromthe media. The operation temperature should be significantly below thetemperature at which the media was made, to prevent the binder softeningenough to release the primary material and to prevent furtherdeformation of the binder. The invented media is especially beneficialin gravity flow water filtration applications.

By using only the two components, without a third material, (that is,without a traditional non-tacky, non-binding support material), themanufacturer is able to obtain a high yield of high active-surface-area,appropriate-pressure-drop media. The preferred methods and compositionsresult in particles that exhibit appropriate packing characteristics ina filter/treatment bed or housing, and that exhibit excellent treatmentperformance. By using the invented methods of manufacture, a high yieldof on-spec product is achieved.

The invented media is called a “two-component” media because it ismanufactured from a binder material and an active material, rather thanfrom a combination of a solid support, a binder material, and an activematerial. By using the term “two-component,” the inventors do not intendto limit the binder to being only one type of polymer, for example, butdo intend to include binders that may comprise one binder or a mixtureof two or more binders that may be softened at temperatures in anappropriate range for causing active material to adhere to the binder(s)and for causing multiple particles of binder to adhere to each other.Also, the inventors do not intend “two-component” to limit the activematerial to being only one type of active material, but rather do intendto include one active material or a mixture of two or more activematerials.

For example, the binder may itself be a mixture of several differentbinder particles, preferably, but not necessarily, exhibiting close tothe same melting/softening point. For example, different polyolefins maybe used, or two different binders wherein one is optimum for creatingvoids and channels in the granules and one that reduces fines.

Likewise, the active material may be a mixture of several differentactive particles for different purposes, preferably, but notnecessarily, being close to the same diameter range. Two or more activematerials selective to different metals or to different species withinthe fluid being treated, may be used. The different active materials maylie in a monolayer or multiple layers in the binders, or, in the“connector” style binder structures, the different active materials maybe stuck together adjacent to each other in a random structure of activeparticles connected by discontinuous globules of binder.

By using a low melt index binder material, the binder is preferablyprevented from encapsulating the active material or covering its activesites, and yet the binder's tackiness at the temperatures used inmanufacture of the media cause the active material(s) to adhere to theoutside surface of the binder and the binder surfaces in the interiorvoids and channels of the granule. The preferred shapes of the supportstructure of the invented granule range from a binder matrix, to agrouping of binder-coated cores, to relatively smaller, discontinuousamounts of binder in-between active particles. The “coating” the supportstructure preferably includes partial or total coating of the binder'souter surface, which translates to the outer surface of the granulebeing coated with active particles and to the granule having manyinterior voids and channels which are defined by binder surfaces insidethe granule being coated with or attached to active particles.Preferably, as discussed above, the various binder structures work toagglomerate the active materials without any support material besidesthe binder, and especially without a third component consisting of alarge solid particulate support at or near the center of the mediagranule.

Compared to prior art materials, the invented granules provide increasedactive surface area, because volume is not taken up by a solid supportparticle that is substantially greater in size than the active material.Some increased pressure drop may be witnessed in the invented mediabecause of the particles of binder and active material being boundtogether, compared to the large solid support particles in the priorart. The combined binder and active material structure in the inventedgranules, however, has sufficient interior void space and channels toprovide acceptable or good pressure drop even in gravity flowapplications, in that the liquid flows into and through the void spacesboth between granules and inside the granules. Further, the increasedmass and exposed surface area of active material in the inventedgranules, compared to prior art three-part granules, results inincreased activity per volume of the media.

Examples of especially-preferred granules which are binder-agglomeratedactive materials include: activated carbon agglomerated with polyolefinbinder; hydrated metal oxide particles (with or without activated carbonactive particles) agglomerated with polyolefin binder; arsenic reductionmaterials such as iron hydroxide agglomerated with various binders; finemetal powders agglomerated with polyethylene binder for chlorineremoval.

EXAMPLE I

Mix 50×200 mesh activated carbon with powdered polyolefin binder(“Microthene FN510” powdered polyolefin binder with nominal 20 micronparticle size), wherein the activated carbon is 85-92 wt-% and thepolyolefin binder is 15-8 wt-% of the mixture.

Uniformly mix and agitate while heating the mixture to between 325-375degrees F., over a period of about 2-10 minutes. Continually agitate orstir the mixture during this process.

Size the resulting granules while warm using screens to 20×50 mesh.Cool.

EXAMPLE II

Mix Alusil Powder of 40-70 micron size (available from SelectoScientific) with “Microthene FN510” powdered polyolefin binder withnominal 20 micron particle size, wherein the Alusil Powder is 65-90 wt-%of the mixture and the binder is 35-10 wt-% of the mixture.Alternatively, the Alusil Power may be 80-90 wt-% of the mixture and thebinder may be 20-10 wt-% of the mixture.

Uniformly mix and agitate while heating the mixture to between 325-375degrees F., over a period of about 2-10 minutes. Continually agitate orstir the mixture during this process.

Size the resulting granules while warm using screens to 20×50 mesh.Cool.

Although this invention has been described above with reference toparticular means, materials and embodiments, it is to be understood thatthe invention is not limited to these disclosed particulars, but extendsinstead to all equivalents within the scope of the following claims.

1. A method of making a granular media water filter, the methodcomprising: providing only a first component and a second component, thefirst component being binder particles of 100-500 U.S. mesh size andhaving melt index of less than or equal to 1 g/10 min, and the secondcomponent being particles of material active for fluid treatment of100-500 U.S. mesh size; and providing no particles larger than theparticles of the first component and the particles of the secondcomponent; mixing together only said first component and said secondcomponent; heating the resulting mixture to a temperature in the rangeof about 275-500 degrees F. to soften said binder particles so that theparticles of the second component adhere to the binder particles to forma plurality of un-sized granules; sizing the un-sized granules to obtaina plurality of separate granules in the range of 75 microns up to about4700 microns; cooling said plurality of separate granules after saidsizing; and loading said plurality of separate granules into a filtervessel for use in filtering fluid; wherein the method further comprisescompression of said mixture when the mixture temperature is above thebinder's softening point and prior to said sizing.
 2. The method ofclaim 1, wherein said sizing results in said plurality of separategranules being in the range of 140 microns up to about 4700 microns. 3.The method of claim 1, wherein said sizing comprises separating anygreater-than-1700-micron granules into more than one 250-1700 microngranule.
 4. The method as in claim 1, wherein the second component isactivated carbon.
 5. The method as in claim 1, wherein the secondcomponent comprises a sorbent material.
 6. The method as in claim 1,wherein the second component comprises a lead sorbent.
 7. The method asin claim 1 wherein the said binder particles have a Vicat softeningpoint in the range of 150-400 degrees F.
 8. The method as in claim 1comprising mixing said first component and said second componenttogether so that the resulting mixture is 8-50 wt-% first component and92-50 wt-% second component.
 9. The method as in claim 1, wherein saidbinder particles are a mixture of particles of two or more polymers. 10.A method of making granular media water filter, the method consistingessentially of: providing polyolefin binder particles in the range of1-150 microns, and providing particles of active material in the rangeof 1-150 microns that are active for water filtration, wherein noparticles larger than said binder particles and said particles of activematerial are provided in the method; mixing together only said binderparticles and said particles of active material; heating the resultingmixture to a temperature in the range of 275-500 degrees F. to softensaid binder particles, wherein the softened binder particles become acentral support core of binder material having an outer surface andinternal surfaces defining void spaces, and said particles of activematerial adhere to the outer surface and the internal surfaces of saidcentral support core to form two-component granules having internalvoids and channels; sizing the two-component granules to a range of140-1700 microns in diameter in diameter; cooling said sizedtwo-component granules after said sizing; and loading said sizedtwo-component granules into a filter vessel for filtering water throughsaid sized two-component granules.
 11. A method of making a granularmedia water filter as in claim 10, wherein said heating is performedwithout compression of said mixture of binder particles and particles ofactive material.
 12. A method of making a granular media water filter asin claim 10, wherein said mixture is compressed when the mixturetemperature is above the binder's softening point and prior to saidsizing.
 13. A method of making a granular media water filter as in claim12, wherein said compressing is performed at pressure in the range of1-30 psi.
 14. A method of making granular media water filter as in claim10, wherein said particles of active material are activated carbon. 15.A method of making granular media water filter as in claim 10, whereinsaid particles of active material are selected from the group consistingof: alumina oxide, titanium hydroxide, and hydrated metal oxide.